BHARAT HEAVY ELECTRICAL LIMITED

TRAINING REPORT ON POWER TRANSFORMER

SU8MI11LD 1C SU8MI11LD 8
MkS AkIkA SINGn V|[ay verma
LN DLk1MLN1 8tech (LN) 4
1n
year
|dea| |nst|tute of techno|ogy
ghaz|abad

PREFACE

Training is one oI the most important aspects oI a management student`s career.It strengthens the
theoretical concept oI a student by providing him/her practical knowledge.Every engineering
student has to undergo training Ior not less than 5 weeks in summer vacations,under the guidance
oI Sr. Engineers in order to become aware oI the real liIe enigineering situation.

To IulIill the said objectives,I undertook a summer training project at Bharat Heavy Electricals
Limited, 1hansi. uring the course oI training, I did a comprehensive study on the topic
POWER TRANSFORMERS.

In this project report I have put my best eIIorts to compile the data to the highest level oI
accuracy.




VI1AY VERMA 3
RD
YEAR
B.TECH (ELECTRICAL & ELECTR ONICS ENGINEERING)
IDEAL INSTITUTE OF TECHNOLOGY, GHAZIABAD


ACKNOWLEDGEMENTS

In the successIul completion oI this project, I am indebted to countless people without whom the
success oI this project was uncertain.First oI all, I would like to convey my sincere thanks to Dr.
Druva Bhargav(Sr.Manager,Human Resource Department,BHEL,1hansi) who gave me the
opportunity to undergo this training.

In particular I express my deep regards to Dr. Santosh Mishra(Training Coordinator,Human
Resource Development,BHEL,1hansi) who had Iaith in me,whispered the words oI
encouragement and made helpIul suggestions Irom time to time.I wish every trainee may get a
project guide who is as cooperative,knowledgeable and supportive as Mishra Sir.

I thank all my Iriends Ior their angelic support,special thanks to those whose names I Iailed to
mention in this report.

And Iinally my heartIelt gratitude to my loving parents Ior enduring the late nights and clicking
keyboard.I want to remain in the debt oI all the people I have mentioned above.

VI1AY VERMA 3
RD
YEAR
B.TECH (ELECTRICAL & ELECTR ONICS ENGINEERING)
IDEAL INSTITUTE OF TECHNOLOGY, GHAZIABAD

A BRIEF INTRODUCTION
8y Lhe end of 3
Lh
flveyear plan lL was envlsaged by Lhe plannlng commlsslon LhaL
Lhe demand for power Lransformer would rlse ln Lhe comlng years AnLlclpaLlng Lhe counLry's
requlremenL 8PLL declded Lo seL up a new planL whlch would manufacLure power and oLher
Lypes of Lransformers ln addlLlon Lo Lhe capaclLy avallable ln 8PLL 8hopal 1he 8hopal planL was
engaged ln manufacLurlng Lransformers of large raLlngs and !hansl unlL would concenLraLe on
power Lransformer upLo 30 kvA 132 kv class and oLher Lransformers llke lnsLrumenL
1ransformer s 1racLlon Lransformers for rallway eLc
1hls unlL of !hansl was esLabllshed around 14 km from Lhe clLy on Lhe nP no 26
on !hansl LallLpur road lL ls called secondgeneraLlon planL of 8PLL seL up ln 1974 aL an
esLlmaLed cosL of 8s 1622 crores lncluslve of 8s 21 crores for Lownshlp lLs foundaLlon was lald
by laLe Mrs lndlra Candhl Lhe prlme mlnlsLer on 9
Lh
!an 1974 1he commerclal producLlon of
Lhe unlL began ln 197677 wlLh an ouLpuL of 8s 33 lacs slnce Lhen Lhere has been no looklng
back for 8PLL !hansl
The plant oI BHEL is equipped with most modern manuIacturing processing and
testing Iacilities Ior the manuIacture oI power, special transIormer and instrument transIormer,
iesel shunting locomotives and AC/C locomotives. The layout oI the plant is well streamlined
to enable smooth material Ilow Irom the raw material stages to the Iinished goods. All the Ieeder
bays have been laid perpendicular to the main assembly bay and in each Ieeder bay raw material
smoothly gets converted to sub assemblies, which aIter inspection are sent to main assembly bay.
The raw material that are produced Ior manuIacture are used only aIter thorough
material testing in the testing lab and with strict quality checks at various stages oI productions.
This unit oI BHEL is basically engaged in the production and manuIacturing oI various types oI
transIormers and capacities with the growing competition in the transIormer section, in 1985-86
it under took the re-powering oI ESL, but it took the complete year Ior the manuIacturing to
begin. In 1987-88, BHEL has progressed a step Iurther in under taking the production oI AC
locomotives, and subsequently it manuIacturing AC/C locomotives also.

PRODUCT PROFILE OF BHEL,1HANSI UNIT
PRODUCTS RATINGS
1. !ER TRANSFRMER U!T 220 KV CLASS 250 MVA.

2. S!ECIAL TRANSFRMER U!T 110 KVA.

3. ES! TRANSFRMER 100 KV,140 MA

4. FREIGHT LC TRANSFRMER 3900 T 5400 KVA & 6500 KVA

5. ACEMU TRANSFRMER U!T 1000 KVA 25 KV(1 !HASE)

6. RY TY!E TRANSFRMER U!T 31.50 KVA

7. INSTRUMENT TRANSFRMER VT&TC U!T 220 KV.

8. IESEL ELECTRIC LCMTIVE U!T 2600 H!

9. AC/C LCMTIVE 5000 H!.
10. ELL AGN 200 TNE.
BBEL 0B}ECTIvES
A dynamlc organlzaLlon ls one whlch keeps lLs alm hlgh Lo adopL lLself qulckly Lo changlng envlronmenL
So here we are ln 8PLL
1he ob[ecLlves of Lhe company have been redeflned ln Lhe corporaLe plan for Lhe 90's
VISIUN
A WorldClass Lnglneerlng LnLerprlse CommlLLed Lo Lnhanclng SLakeholder value
MISSIUN
1o be an lndlan MulLlnaLlonal Lnglneerlng LnLerprlse provldlng 1oLal 8uslness SoluLlons Lhrough CuallLy
roducLs SysLems and Servlces ln Lhe flelds of Lnergy lndusLry 1ransporLaLlon lnfrasLrucLure and oLher
poLenLlal areas
VALUES
eal Lo Lxcel and esL for Change
lnLegrlLy and lalrness ln all MaLLers
8especL for ulgnlLy and oLenLlal of lndlvlduals
SLrlcL Adherence Lo CommlLmenLs
Lnsure Speed of 8esponse
losLer Learnlng CreaLlvlLy and 1eamwork
LoyalLy and rlde ln Lhe Company

nLAL1n SAIL1 AND LNVIkCNMLN1 MANAGLMLN1
8PLL as an lnLegral parL of buslness performance and ln lLs endeavor Lo becomlng a world class
organlzaLlon and sharlng Lhe growLh global concern on lssues relaLed Lo LnvlronmenL
CccupaLlonal PealLh and SafeLy ls commlLLed Lo proLecLlng LnvlronmenL ln and around lLs own
esLabllshmenL and provldlng safe and healLhy worklng envlronmenL Lo all lLs employees
lor fulfllllng Lhese obllgaLlons CorporaLe ollcles have been formulaLed as

ENVIRUNMENTAL PULICY
O Compllance wlLh appllcable LnvlronmenLal LeglslaLlon/8egulaLlon
O ConLlnual lmprovemenL ln LnvlronmenL ManagemenL SysLems Lo proLecL our naLural
envlronmenL and conLrol polluLlon
O romoLlon of acLlvlLles for conservaLlon of resources by LnvlronmenLal ManagemenL
O LnhancemenL of LnvlronmenLal awareness amongsL employees cusLomers and suppllers
UCCUPATIUNAL HEALTH AND SAFETY PULICY
O Compllance wlLh appllcable LeglslaLlon and 8egulaLlons
O SeLLlng ob[ecLlves and LargeLs Lo ellmlnaLe/conLrol/mlnlmlze rlsks due Lo CccupaLlonal and
SafeLy Pazards
O ApproprlaLe sLrucLured Lralnlng of employees on CccupaLlonal PealLh and SafeLy (CPS)
aspecLs
O lormulaLlon and malnLenance of CPS ManagemenL programmes for conLlnual lmprovemenL
O erlodlc revlew of CPS ManagemenL SysLem Lo ensure lLs conLlnulng sulLablllLy adequacy and
effecLlveness
O CommunlcaLlon of CPS ollcy Lo all employees and lnLeresLed parLles

SECTINS F BHEL JHANSI UNIT
8PLL has many deparLmenLs whlle producLlon and admlnlsLraLlve deparLmenLs are separaLe
8roadly speaklng 8PLL has LhreeproducLlon caLegorles

1ransformer sect|on
2 Loco sect|on
3 8us Duct









1kANSICkMLk SLC1ICNS
18AnSlC8ML8 CCMML8ClAL (18C)
1he ob[ecLlve of Lhe deparLmenL ls lnLeracLlon wlLh Lhe cusLomers lL brlngs ouL Lenders and
noLlces and also responds Lo Lhem lL ls Lhls deparLmenL LhaL bags conLracLs of bulldlng Lransformers
AfLer dellvery regardlng faulLs Lhls deparLmenL does fallures and malnLenance All such snags are
reporLed Lo Lhem and Lhey forward Lhe lnformaLlon Lo Lhe concernlng deparLmenL
Cne of Lhe ma[or Lask of Lhls deparLmenL ls Lo earn decenL proflLs over all negoLlaLlons 1ransformer
lndusLry has become very compeLlLlve 1he company offerlng Lhe lowesL prlce geLs Lhe conLracL buL Lhls
process may conLlnue does Lhe work on very low proflLs 1o avold such a slLuaLlon a body by Lhe name
of lndla LlecLrlcal ManufacLures AssoclaLlon (lLMA) was seL up 1hls assoclaLlon helps Lo malnLaln a
healLhy compeLlLlve aLmosphere ln Lhe manufacLurlng of elecLrlcal appllances
1he maln work of Lhe 18C ls classlfled as
1enders and noLlces
lnLeracLlon wlLh deslgn deparLmenL
lace of Lhe work
ApproxlmaLe cosL of Lhe work
LarnesL money
1he place and Llme where conLracL documenLs can be seen
1he place and Llme where Lender documenLs can be obLalned
1he Llme up Lo whlch Lhe Lender documenLs wlll be sold
1he amounL lf any Lo be pald for such documenLs
1he place and Lhe daLe and Lhe Llme when Lenders are Lo be submlLLed and are Lo be opened

1kANSICkMLk LNGINLLkING (1kL)
1he Lransformer manufacLured ln 8PLL !hansl range from 10 MvA Lo 240 MvA and up Lo 220 kv 1he
varlous Lransformer manufacLured ln Lhls unlL are
ower transformer
a) CeneraLor Lransformer
b) SysLem Lransformer
c) AuLo Lransformer
Spec|a| transformer
a) lrelghL loco Lransformer
b) LS Lransformer
c) lnsLrumenL Lransformer
d) ury Lype Lransformer
All above Lypes are oll cooled excepL dry Lype whlch are alrcooled
1he generaLed volLages aL Lhe power sLaLlon are 69 kv 11 kv and 138 kv buL due Lo cerLaln
advanLages llke economlcal generaLlon 11 kv ls Lhe mosL wldely used lor Lhls volLage needs Lo be
sLepped up 1ransmlsslon aL hlgh volLage ls deslrable because lL resulLs ln lesser losses needs Lhlnner
wlre and hence ls economlcal lf Lhe currenL ls kepL hlgh Lhe copper losses become very hlgh buL lron
losses are pracLlcally consLanL

ln cerLaln cases Lhe requlred volLage may be less Lhan Lhe ouLpuL volLage so ln order Lo obLaln lL we
requlre a Lapplng clrculL 1he ouLpuL volLage may have a cerLaln percenLage varlaLlon whlch may be
Lapped ln 4 or 6 equal sLeps

1he Lype of Lap changer depends on Lhe appllcaLlon of Lhe Lransformer Where a conLlnuous power
supply ls noL requlred an Cff ClrculL 1ap Changer (CC1C) may be used Where a conLlnuous power
supply ls a musL eg aL a sub sLaLlon ln clLles eLc Cn Load 1ap Changer (CL1C) ls used













IA8kICA1ICN
labrlcaLlon ls noLhlng buL producLlon lL comprlses of 03 bays le 8ay0 8ay1 8ay 2

BAY-0:
It is the preparation shop while the other two bays Iorm the assembly shop.
This section has the Iollowing machines :
4 !lanner machine To reduce thickness
4 Shearing machine
4 CNC / ANC Flame Cutting machine To cut
Complicated shaIt items using xy-Acetylene Ilame
4 Bending machine
4 Rolling machine
4 Flattening machine
4 rilling machine
4 Nibbling machine
4 !entagraph Ilame cutting machine





BAY-1:
It is an assembly shop where diIIerent parts oI tank come Irom bay 0.Here welding
processes are used Ior assembly, aIter which a rough surIace is obtained Grinder
operating at 1200 rpm is used to eliminate the roughness.
BAY-2:
It is an assembly shop dealing with making diIIerent objects mentioned below.
11ank assembly 3cross feed assembly
21ank cover assembly 6core clamp assembly
3Lnd lrame assembly 7pln and pad assembly
4fooL assembly
8efore assembly shorL blasLlng (flrlng of small maLerlals le acld plckLlng) ls done on dlfferenL
parLs of [obs Lo clean Lhe surface before palnLlng
AfLer assembly some LesLs are done known as NON u51kuc1lv 151
U|trason|c test Lo deLecL Lhe weldlng faulL on Lhe C8C aL Lhe faulL place hlgh
ampllLude waves are obLalned
2 D|e enetrat|on test 8ed soluLlon ls puL aL Lhe weldlng and Lhen cleaned AfLer some
Llme whlLe soluLlon ls puL Appearance of a red spoL lndlcaLes a faulL aL Lhe weldlng
3 Magnet|c crack detect|on MagneLlc fleld ls creaLed and Lhen lron powder ls puL aL Lhe
weldlng SLlcklng of Lhe lron powder ln Lhe weldlng lndlcaLed a faulL
4 Okay 1est lL ls same as human LesLlng and Lhe faulL ls seen ln xray fllm

Pere are baslcally Lhree secLlons ln Lhe bay

1 Machlne secLlon
2 Copper secLlon
3 1oollng secLlon

MACnINL SLC1ICN
1he operaLlons Lo form small componenLs of power and LracLlon Lransformer are done ln Lhls
secLlon 1he shop conslsL of followlng machlnes
CLN1kAL LA1nL lL conslsL one LallsLock headsLock lower parL of LallsLock ls flxed and Lall sLock
splndle ls movlng Cn Lhls machlne faclng Lurnlng and Lhreadlng ls done
1UkkL1 LA1nL lLs funcLlon ls same as cenLral laLhe buL lL ls used for mass producLlon Pere
LurreL head ls used ln presence of LallsLock because LurreL head conLalns many LallsLocks
around slx
CAS1AN LA1nL lL ls belL drlve
kADIAL AkM DkILLING MACnINL lL ls used for drllllng and borlng
nCkI2CN1AL 8CkING MACnINL lL ls compuLerlzed and used for maklng bore faclng eLc
MILLING MACnINL
a) PorlzonLal mllllng machlne lL ls used for maklng gear and cuLLlng operaLlons
b) verLlcal mllllng machlne 8y Lhe machlne faclng cuLLlng and 1sloL cuLLlng ls done

CCLk SLC1ICN
All Lhe processes relaLed Lo copper are done here
1U8L SLI11ING MACnINL 1hls machlne ls developed here and ls used for cuLLlng Lhe Lube along
lLs lengLh and across lLs dlameLer lLs blade Lhlckness ls 3mm
SnLAkING MACnINL ll ls operaLed hydraullcally and lLs blade has vshape and a Lhlckness of
13mm
DIL AND UNCnING MACnINL lL ls also hydraullcally operaLed and has a dle and punch for
maklng holes
nDkAULIC 8LNDING MACnINL lL ls used for bendlng Lhe [ob upLo 90
SnLAkING MACnINL lL ls fully mechanlcal and ls used Lo cuL Lhe [ob along lLs wldLh
IL kLSS MACnINL lL ls used Lo press Lhe [ob lL ls operaLed mechanlcally by a wheel whlch ls
on Lhe Lop of Lhe machlne

8LND SAW MACnINL 1hls machlne ls used for cuLLlng [ob havlng small Lhlckness lL has a
clrcularly operaLed blade around 31 mLr long
WA1Lk CCCLLD 8kA2ING MACnINL lL conLalns Lwo carbon brushes 1he sheeL ls puL along wlLh
a sulfas sheeL and Lhe carbon brushes are heaLed A Lap !olnL ls formed beLween Lhe sheeLs as
Lhe sulfas sheeL melLs
LINCING 8LL1 MACnINL lL creaLes a smooLh surface
nDkAULIC kLSS MACnINL 1o press Lhe [ob
SCLDLk C1 MACnINL lL has a poL LhaL conLalns solder Solder has a composlLlon of 60 n
and 40 b

1CCLING SLC1ICN
ln Lhls secLlon Lhe servlclng of Lools ls done
8LADL SnAk MACnINL lL sharpens Lhe blade uslng a clrcular dlamond cuLLer 8lade of CnC
cropplng llne machlne ls sharpened here
MINI SUkIACL GkINDLk MACnINL lL serves grlndlng purposes lL has a grlndlng wheel made of
Alumlnlum Cxlde"
1CCL SUkIACL GkINDING MACnINL 1hls ls speclally used Lo grlnd Lhe Lools used ln 8ay 7
DkILL GkINDING MACnINL 1o grlnd Lhe drllls



8A 4
lL ls Lhe wlndlng secLlon
1LS CI WINDING 18everse secLlon wlndlng
2Pellcal wlndlng
3Splral wlndlng
4lnLerleaved wlndlng
3Palf secLlonal wlndlng
1here are four 1LS CI CCIL flxed ln a Lransformer Lhey are
1 Low volLage coll (Lv)
2 Plgh volLage coll (Pv)
3 1erLlary coll
4 1ap coll

1he Lype of wlndlng depends upon [ob requlremenL Also Lhe wldLh and Lhlckness of Lhe
conducLors are deslgned parLlculars and are declded by deslgn deparLmenL ConducLors used
for wlndlng ls ln Lhe form of very long sLrlps wound on a spool Lhe conducLor ls covered by
cellulose paper for lnsulaLlon

lor wlndlng flrsL Lhe mould of dlameLer equal Lo lnner dla meLer of requlred coll ls made 1he
speclflcaLlon of coll are glven ln drawlng 1he dlameLer of mould ls ad[usLable as lLs body ls
made up of wooden secLlons LhaL lnLerlock wlLh each oLher 1hls lnLerlocklng can be lncreased
or decreased Lo ad[usL Lhe lnner dlameLer of coll

1he moulds are of followlng Lypes
1 8elly Lypes
2Llnk Lypes
3 Cone Lype

AY-:
lL ls core and punch secLlon 1he lamlnaLlon used ln power dry LS Lransformer eLc for
maklng core ls cuL ln Lhls secLlon
C8CC(cold rolled graln orlenLed) slllcon sLeel ls used for lamlnaLlon whlch ls lmporLed ln lndla
from !apan uk Cermany lL ls avallable ln 027 and 028 mm Lhlck sheeLs 1mL wlde and
measured ln kg1he sheeL s are coaLed wlLh very Lhln layer of lnsulaLlng maLerlal called
carllLes"
lor Lhe purpose of cuLLlng and punchlng Lhe core Lhree machlnes are lnsLalled ln shop
SLI11ING MACnINL lL ls used Lo cuL C8CC sheeLs ln dlfferenL wldLh lL has a clrcular cuLLer
whose poslLlon can be changed as per Lhe requlremenL
2 CNC CkCING LINL NLUMA1IC lL conLalns only one blade whlch can roLaLe 90 abouL Lhe
sheeL lL ls operaLed pneumaLlcally
3 CNC CkCING LINL nDkAULIC lL ls also used Lo cuL Lhe C8CC sheeL lL conLalns Lwo blades
one ls flxed and Lhe oLher roLaLes 90 above Lhe sheeL lL ls operaLed hydraullcally M4 quallLy
sheeL 023033 mm Lhlckness ls used

AY-:
Slnglephase LracLlon Lransformer for AC locomoLlves ls assembled ln Lhls secLlon 1hese
lrelghL locomoLlve Lransformers are used where Lhere ls frequenL change ln speed ln Lhls bay
core wlndlng and all Lhe assembly and LesLlng of LracLlon Lransformer ls done

1hreephase Lransformers for ACLMu are also manufacLured ln Lhls secLlon 1he supply llnes
for Lhls Lransformer ls of 23 kv and power of Lhe Lransformer ls6300 kvA
1he Lap changer of recLlfler Lransformer ls also assembled ln Lhls bay 8ecLlfled Lransformer ls
used ln blg furnace llke Lhe Lhermal power sLaLlons / planLs ( 1)

8A7
1hls ls Lhe lnsulaLlon shop varlous Lypes of lnsulaLlons are
AWWW All Wood WaLer Washed press paper
1he paper ls 0203mm Lhlck cellulose paper and ls wound on Lhe
conducLors for lnsulaLlon
2-PRE-COMPRESSED BOARD: This is widely used Ior general insulation & separation
oI conductors in the Iorms oI blocks.
3kLSS 8CAkD 1hls ls used for separaLlon of colls eg Lv from Pv lL ls up Lo 38 mm Lhlck
4UDLL unuemnlfled LlecLrlcal LamlnaLed wood or ermawood
1hls ls speclal Lype of plywood made for lnsulaLlon purposes
SII8kL GLASS 1hls ls a resln maLerlal and ls used ln flre pron areas
68AkLLLI1L
7GASkL1lL ls used for proLecLlon agalnsL leakage
8SILICCN kU88Lk SnLL1lL ls used for dry Lype Lransformer
1he machlnes used for shaplng Lhe lnsulaLlon maLerlal are
1Cyllndrlcal machlnes
2Clrcle cuLLlng machlne
3 Scarflng machlnes
4unchlng press machlne
3urllllng machlne
6CullleLln machlnes
78ench saw (spl for Cu)
8!lg saw (spl for lu)
9Clrcular saw
10Llnesln machlnes

BAY 8:
lL ls Lhe lnsLrumenL Lransformer and LS Lransformer manufacLurlng secLlon

INS1kUMLN1 1kANSICkMLk
1hese are used for measuremenL AcLual measuremenL ls done by measurlng lnsLrumenLs buL
Lhese Lransformers serve Lhe purpose of sLepplng down Lhe volLage Lo proLecL Lhe measurlng
lnsLrumenL 1hey are used ln AC sysLem for measuremenL of currenL volLage and energy and
can also be used for measurlng power facLor frequency and for lndlcaLlon of synchronlsm
1hey flnd appllcaLlon ln proLecLlon of power sysLem and for Lhe operaLlon of over volLage
over currenL earLh faulL and varlous oLher Lypes of relays

1hey are of Lwo Lypes
1CurrenL Lransformer (C1)
2volLage Lransformer (v1)
CURRENT TRANSFORMER-
It is a step down transIormer. High current is not directly measured by the CT but is
stepped down to lower measurable voltages.

BODY:
O The main body is a bushing, which houses the winding and also acts as
an insulator.
O 1he C1 has a boLLom and Lop chamber
O 1he Lop chamber ls a cyllndrlcal Lank of mlld sLeel lL has Lermlnals for
connecLlon of Pv colls lL also has a glass wlndow Lo lndlcaLe Lhe oll level
O 8elow Lhe Lop chamber ls Lhe bushlng made of porcelaln lL has several folds or raln
sheds" Lo provlde a speclflc elecLrlc fleld dlsLrlbuLlon and long leakage paLh Some bushlngs
are cyllndrlcal whlle modern ones are conlcal as amounL of oll porcelaln used ls reduced
wlLhouL any undeslrable defecL
O 8oLLom chamber houses Lhe secondary wlndlng 1here ls also connecLlon box Lo whlch
Lhe connecLlon of Lhe low volLage (Lv) coll ls made

WlnulnCS
1he prlmary wlndlng conslsL of hollow copper/alumlnum plpe benL ln form of a 'u' alumlnum ls
used for low raLlng lor hlgher raLlng a seL of wlres ls passed Lhrough Lhe plpe lor sLlll hlgher
raLlngs a copper plpe ls used and for hlghesL raLlng copper plpe wlLh copper wlres passlng
Lhrough lL ls used 1hls arrangemenL depends on Lhe currenL carrylng capaclLy 1he benL porLlon
of prlmary as ln Lhe boLLom chamber where as Lhe free end ls Lhe Lop chamber 1he sLralghL
porLlon lles lnslde Lhe bushlng
1he prlmary ls wound wlLh crepe paper lnsulaLlon 1he Lhlckness of Lhe lnsulaLlon goes ln
lncreaslng as we go downwards ln Lhe boLLom chamber 1he free ends are provlded wlLh
'ferrules' whlch are small hollow cyllnders Lhrough whlch wlres can pass connecLlon Lo Lhe
prlmary are made Lhrough Lhese ferrules

1he secondary ls dlvlded ln a number of colls for dlfferenL seL of Laplngs ConnecLlons are
dlfferenL Laplngs are made ln connecLlon box Lach coll has an annular core of C8CC (slllcon
sLeel) 1he wlre use ls lnsulaLed copper wlre 1he wlndlng may be done boLh manually and by
machlne AfLer wlndlng Lhe colls are covered wlLh paper Lape lnsulaLlon 1he colls are Lhen
sllpped lnLo boLh Lhe legs of Lhe prlmary wlndlng and connecLlons are made ln connecLlon box
for dlfferenL Lapplng

vCL1ACL 18AnSlC8ML8S
1hls ls also a sLepped down Lransformer 1he ouLer consLrucLlon ls same as LhaL of Lhe C1 LhaL ls
Lhls also has a Lop chamber bushlng and a boLLom chamber 1he dlfference ls only ln Lhe
wlndlng

WlnulnCS
1he prlmary wlndlng ls of Lhe Lhlck wlre havlng a few Lurns 1he wlndlng ls heavlly lnsulaLed wlLh
paper lnsulaLlon lL has a hollow cyllnder passlng cenLrally Lhrough lL whlch houses Lhe
secondary wlndlng 1he clean and palnLed wlLh elLher enamel or epoxy palnL 1he cusLomer
glves Lhe cholce of palnL Lpoxy palnL ls generally used ln chemlcal planLs and seashore
lnsLallaLlon 1ermlnals are Lhen mark and raLlngs and dlagram plaLe ls flxed
1he [ob ls Lhen senL Lo Lhe shlpplng deparLmenL whlch Lakes care of lLs dlspaLch by packlng lL ln
Lhe wooden boxes

LS 18AnSlC8ML8
1he LlecLrosLaLlc reclplLaLor Lransformer ls used for envlronmenLal appllcaLlon lL ls used Lo
fllLer ln a suspended charge parLlcle ln Lhe wasLe gases of an lndusLry 1hey are of parLlcular use
ln Lhermal power sLaLlons and cemenL lndusLry
1he LS ls a slnglephase Lransformer lL has a prlmary and secondary 1he core ls lamlnaLed and
ls made up of C8CCS lL ls a sLep up Lransformer An AC reacLor ls connecLed ln serles wlLh
prlmary coll 1he ouLpuL of Lhe Lransformer musL be uC Lhe ls obLalned by recLlfylng AC uslng a
brldge recLlfler (brldge recLlfler ls a comblnaLlon of several hundred dlodes) A radlo frequency
choke (8l choke) ls connecLed ln serles wlLh Lhe uC ouLpuL for Lhe proLecLlon of Lhe secondary
clrculL and fllLer clrculL 1he ouLpuL ls chosen negaLlve because Lhe parLlcles are poslLlvely
charged 1he uC ouLpuL from Lhe secondary ls glven Lo a seL of plaLes arrange one afLer Lhe
oLhers lmpurlLy parLlcles belng poslLlvely charged sLlck Lo Lhese plaLes whlch can be [erked off
lor Lhls a neLwork of plaLes has Lo be seLup all across Lhe planL 1hls ls very cosLly process ln
comparlson wlLh Lhe Lransformer cosL A rellve venL ls also provlded Lo prevenL Lhe Lransformer
from bursLlng lL hlgher pressure develops lnslde lL lL ls Lhe weakesL polnL ln Lhe Lransformer
body An oll LemperaLure lndlcaLor and Lhe secondary supply spark deLecLor are also provlded

Cne slde of Lhe Lransformer ouLpuL ls Laken and oLher slde has an 'marshalllng box' whlch ls Lhe
conLrol box of Lhe Lransformer


BAY-9:
In this bay power transIormer are assembled. AIter taking diIIerent input Irom diIIerent
bays 0-9 assembly is done
!ower transIormer is used to step and step down voltages at generating and sub-stations.
There are various ratings 11KV, 22KV, manuIactured, they are
a) Generator transIormer.
b) System &
c) AutotransIormer.
A transIormer in a process oI assemblage is called a job. The design oI the transIormer is
done by the design deptt. & is unique oI each job; depends on the requirement oI
customer. The design department provides drawing to the assembly shop, which
assembles it accordingly.
The step involved in assembly are:
1. Core building
2. Core LiIting.
3 unlaclng
4 uelaclng and endframe mounLlng
3 Plgh volLage Lermlnal gear and low volL Lermlnal gear mounLlng
6 vapour phaslng and oll soaklng
7 llnal servlclng and Lanklng
8 Case flLLlng
Core 8ulldlng
lL ls made of cold rolled graln orlenLed sLeel 'C8CC' 1he punched core ls senL Lo Lhls shop
from core punchlng shop Pere lL ls assembled wlLh Lhe help of drawlng a seL of 4 lamlnaLlons ls
called a packeL 1he verLlcal porLlon of Lhe core ls called a 'leg' Lhe horlzonLal one ls called as 'yoke'
ackeLs of boLh are lnLerllnked lL ls undeslrable Lo keep Lhe x secLlon of core clrcular Lo provlde low
relucLance parL wlLh ouL alr space A perfecL clrcle can noL be made so Lhe core ls sLepped Lo achleve
a near clrcle WhaLever spaces lefL are fllled wlLh Lhln wooden rod AfLer core bulldlng Lhe end
frames are bolLed 1he bolLs are lnsulaLed from Lhe core

Core LlfLlng
1he core ls llfLed by a crane and ls placed verLlcal 1he resL of assembly ls done on Lhe core
ln Lhls poslLlon
unlaclng Core Coll Assembly
1he yoke of Lhe core ls removed uslng crane 8oLLom lnsulaLlon ln form of 30MM Lhlck uuLL
sheeLs ls placed C8 and press board are also used for fllllng Lhe gap and Lo provlde a good base
for Lhe coll Lo resL 1he coll are Lhen lowered prlmary secondary LerLlary and Lap ln LhaL
sequences
8elaclng Lndframe MounLlng
AfLer lowerlng a coll Lhe Lop lnsulaLlon slmllar Lo Lhe boLLom one ls provlded 1he removed yoke
ls placed endframe bolLed back lnLo lLs poslLlon
1he connecLlons are Lhen made as per drawlngs All Lhe conducLors are lnsulaLed uslng crepe
paper 8razlng copper makes Lhe connecLlons lor brazlng sllphos ls used
1he followlng LesLs are done durlng re laclng
1 Megger 1esL
2 8aLlo LesL
3 Meg currenL / Plgh volL LesL
1esLlng aL Lhls sLage ls called pre LesLlng 1hls ls essenLlal because lf false are seen aL a laLer
sLage whole of Lhe Lransformer wlll have Lo be dlssembled
Pv1C Lv1C
1ermlnals gears are accessorles provlded aL hlgh volLage and low volLage Lermlnals Maln devlce
used ls Lap changer 1ap changer can be on load or offload ln offload Lype Lhe supply has Lo be
Lrlpped Lhen Lhe Laplngs changes buL ln on load Lype Lhe Laplngs can be changed whlle Lhe
supply ls on Cn load Lap changer (CL1C) are used where Lhe supply ls deslred Lo be conLlnuous

1he upper porLlon of Lhe CL1C conLalns mechanlsm by whlch Lapplng ls changed 1here ls swlLch
whlch changes Lap ln very small Lype (Mlcroseconds) 8uL Lhere ls a posslblllLy of sparklng 1o
geL rld of lL CL1C lS fllled wlLh oll 1he boLLom parL houses Lhe Lermlnals and Lhe mechanlsm
whlch makes auLomaLlc connecLlons
1he Lermlnals are made of Lhlck alumlnum sLrlps

vapour haslng Cll Soaklng
lL ls well known facL LhaL waLer (lmpure) ls a conducLor elecLrlclLy 1herefore molsLure presence
ln Lransformer wlll effecL lnsulaLlon Lhe process of molsLure removal from Lransformer ls called
vapour phaslng
1he [ob ls puL ln dummy Lype and place ln a vacuum vessel lL ls an alrLlghL chamber wlLh heaLlng
faclllLles A solvenL vessel ls released ls Lhe chamber whlch enLers all Lransformer parLs and
lnsulaLlons lL absorbs waLer rapldly 1he [ob ls heaLed ln vacuum All Lhe solvenL vapours are
sucked ouL wlLh molsLure MeLals conLaln no molsLure buL a loL of lnsulaLlons ls provlded whlch
conLalns Lhls molsLure and lf noL Laken care of may bursL Lhe [ob
AfLer molsLure removal Lank ls fllled wlLh Lransformer oll and soaked for aL leasL Lhree hours so LhaL
every geLs weL wlLh oll1he [ob remalns ln vessel for Lhree days durlng phaslng lL ls Lhen Laken ouL of
Lhe vessel and also ouL of Lhe dummy Llme

llnal Servlclng 1anklng
AfLer Laklng Lhe [ob ouL of dummy Llme all Lhe parLs reLlghLened any oLher defecLs are recLlfled
and [ob ls reLlmed ln mlld sLeel Lank AfLer Lanklng oll ls fllled
Case llLLlng
1he accessorles are flxed and flnal Louches glven Lo [ob 1he accessorles lnclude Lank cover
flxlng bushlng flxlng valves eLc 1he Lermlnals are marked and 8 and u (8aLlng and ulagram)
plaLe ls flxed 8olLlng and noL rlveLlng because lL may requlre malnLenance and hence openlng
close Lhe Lank
8ushlngs are hollow Lo provlde a passage for conducLor oll ls fllled lnslde Lhe hollow spaces for beLLer
lnsulaLlon 8ushlng ls bullL on a mlld sLeel base whlch ls bolLed Lo boLLom chamber wlLh a cork gaskeL
ln vacuum
1he boLLom chamber ls mlld sLeel Lank wlLh a sLeel frame aLLached Lo lLs base for earLhllng
1hls chamber houses Lhe secondary wlndlng
S1C8L
1here are Lhree secLlons ln sLore
O ConLrol 8ecelvlng SecLlon
O CusLody SecLlon
O Scrap ulsposal SecLlon
lunC1lCnS
llsL of maLerlal comlng ln sLores ls prepared and CuallLy ConLrol people are called for
lnspecLlon lf maLerlal ls found as per sLandard S8v (SLore 8ecelpL voucher) ls lssued for each
maLerlal A LoLal of 08 S8v's are prepared Some maLerlals such as Slllcon oll 1ransformer oll
lnsulaLlng maLerlal eLc are dlrecLly sLored ln Lhe 8ays




LOCO SECTION :
LOCOMOTIVE PRODUCTION(LMP):
1here are Lwo producLs
O AlLernaLlng CurrenL LocomoLlve (ac Loco)
WAC3P
AC/uC Loco
4 WCAM2
4 WCAM3
Wbroad gauge Arunnlng ln AC mode
Crunnlng ln uC mode Chaullng goods Lraln
haullng passenger Lraln Mhaullng passenger goods Lraln
O ulesel LlecLrlc LocomoLlve ShunLlng (uLSL)
330 P
700 P
4 Slngle ower ack (S) Cne 700 P m/c ls made as a slngle unlL lL ls a meLer gauge
locomoLlve
4 1wln ower ack (1) 2 330P m/cs are comblned ln 1 englne can be operaLed
lndlvldually or ln comblnaLlon dependlng on Lhe load
430 P
1400 P
1130 P
1330 P
2600 P
1130 P and 1330 P uLSL s are nonsLandard locomoLlves and are modlfled verslons of 1400
P uLSL based on requlremenL of cusLomer

Under mention are the new non-conventional products designed and developed Ior
Indian Railways based on their requirement.
HE (verhead electric) recording and testing cars
u1v(uLlllLy vehlcle )
88v(8all cum road vehlcle)
uL1v( ulesel elecLrlc Lower car)
88v(8aLLery power road vehlcle)
8CM(8lasL cleanlng machlne)
200 1 Well wagon for 8PLL Parldwar
MeLro 8akekolkaLa MeLro 8allways

L0C0N0TIvE NAN0FACT0RINu (LNN):
1hls secLlon deals wlLh manufacLurlng of locomoLlves
1he maln parLs of Lhe locomoLlve are
under frame 1he frame on whlch a locomoLlve ls bullL
Super sLrucLure 1he body of locomoLlve ls called supersLrucLure or Shell and ls
made of sheeL of Mlld sLeel
uC moLor
AlLernaLor
Compressor
llower
SLaLlc 8ecLlflerMS8
SLaLlc ConverLerSC
Lxchanger
8ogle1he wheel arrangemenL of a loco ls called a bogle A bogle essenLlally conLalns
1wheel axle arrangemenL
2Suspenslon
38rake rlgglng
1racLlon Lransformer lL ls flxed on under frame and geLs supply from an overhead llne
by equlpmenL called penLograph 1he Lype of penLograph depends on supply 1hls Lransformer
sLeps down volLage and ls flLLed wlLh a Lap changer ulfferenL Laps are Laken from lL for
operaLlng dlfferenL equlpmenL Cne Lap ls Laken and ls recLlfled lnLo uC uslng MS8 and ls fed
Lo Lhe uC moLor

8allways has Lwo Lypes of power supplles 23 kv 1 hase 30hz AC
1300 v uC
An AC/uC loco ls able Lo work on boLh of Lhese supplles lor eg WCAM3

WCkk LNGINLLkING SLkVICLS (WLS)
1hls deparLmenL looks afLer Lhe commlsslonlng and malnLenance of all Lhe machlnery used ln
Lhe facLory lL also has 3 LwosLage alr compressors for supplylng compressed alr Lo Lhe
varlous bays
1he deparLmenL has 03 dlfferenL dlvlslons
LlecLrlcal Lngg
LlecLronlcs Lngg
Mechanlcal Lngg

LLLC1kICAL LNGINLLkING 1hls dlvlslon looks afLer all Lhe elecLrlcal machlnery and power
dlsLrlbuLlon of Lhe facLory Snags deLecLed ln Lhe sysLem are lmmedlaLely reporLed Lo Lhls depL
by Lhe concernlng depLWLS Lakes prompL acLlon Lo recLlfy lL
1he facLory has a feeder of 11kv 1he LoLal load sancLloned for Lhe facLory ls 2300MvA

8uL Lhe maxlmum demand reaches Lhe range of 17002000 MvA
here are varlous subsLaLlon (SS) lnslde Lhe facLory for dlsLrlbuLlon of power Lo dlfferenL
secLlons
SS 1 Supplles 8ay6 Lo 8ay 9
SS 3 Supplles 8ay 1Lo 8ay4
SS 4 Supplles 8oller and loco planL
SS 3 Supplles 8ay 3
SS 6 Supplles AdmlnlsLraLlve bulldlng

TECBN0L0uY:
1hls deparLmenL analyses Lhe changes Laklng place ln Lhe world and suggesL changes
accordlngly 1hls ls very lmporLanL because Lhe producLs musL noL geL obsoleLe ln Lhe markeL
oLherwlse Lhey wlll be re[ecLed by Lhe cusLomer

IUNC1ICNS
1echnology funcLlons can be classlfled as
rocess|ng Sequence 1he sequence of process of manufacLurlng ls declded for Llmely
and economlc compleLlon of Lhe [ob
Cperat|on t|me est|mate lL lncludes lncenLlve scheme managemenL

A||owed operat|on t|me lL lncludes lncenLlve amounL
Iac|||t|es |dent|f|cat|on lL lncludes looklng for new equlpmenL or planL or Lools Lo
lncrease producLlvlLy
Spec|a| process cert|f|cat|on Speclal processes are Lhe ones requlrlng experLlse for
example ldenLlfylng errors cracks alr bubbles ln weldlng
Spec|a| too|s requ|rement Speclal Lools are alloLLed lf posslble when requlred else
Lhe deslgn has Lo be reconslder
roduct|v|ty pro[ects comp||at|on lL lncludes Lhe lnlLlal analysls of Lhe problem and
Lhelr approprlaLe soluLlon Lo enhance producLlvlLy
1he prlnclple of worklng ls LhaL "ll YOu uO NO1
M4k 1n cn4N65 lN YOuk cOMP4NY 1n cu51OMk wlLL cn4N6 YOu"
CLN1kAL UALI1 SLkVICL
llrsL we geL acqualnLed wlLh a few Lerms concernlng Lhls deparLmenL
UALI1
lL ls Lhe exLenL Lo whlch producLs and servlces saLlsfy Lhe cusLomer needs
UALI1 ASSUkANCL
All Lhose planLs and sysLemaLlc acLlon necessary Lo provlde adequaLe confldence LhaL a producL or
servlce wlll saLlsfy Lhe glven requlremenL ls called quallLy assurance
UALI1 CCN1kCL
1he operaLlonal Lechnlque and acLlvlLles LhaL are used Lo fulflll requlremenL for quallLy are quallLy
conLrol

UALI1 INSLC1ICN
AcLlvlLles such as measurlng LesLlng gauglng one or more characLerlsLlcs of a producL or servlce and
comparlng Lhese wlLh speclfled requlremenL Lo deLermlne conformlLy are Lermed quallLy lnspecLlon


kCILC1 kLCk1
CWLk 1kANSICkMLkS

W 1he ma[or componenLs of power Lransformers are
Core
Wlndlng
1ank labrlcaLed flLLlngs Accessorles
Marshalllng 8ox 81CC panel
1ransformer Cll
8adlaLors fans pumps or ClWl coolers
CL1C
8ushlngs
lnsLrumenLs C1l W1l 8v 8uchholz relay MCC Cll Wll eLc
Core of Lransformer conslsLs of
C8CCS SLeel
Mlld SLeel for Lnd frames
P1S for clamp plaLe
ressboard lnsulaLlon
lnsulaLed ?oke bolL
Core ls one of Lhe subassembly whlch ls requlred ln Lhe beglnnlng of manufacLure of
Lransformer lLs manufacLure ls also sLarLed aL Lhe beglnnlng
Wlndlngs of Lhe Lransformer conslsLs of
aper lnsulaLed copper ConducLor
ConLlnuously 1ransposed ConducLor
lC/ S88/ recompressed ressboard Cyllnders
ressboard for uoveLall 8locks SLrlps
Wlndlngs are also sLarLed along wlLh core ln Lhe beglnnlng of manufacLure of
Lransformer

AfLer Core Wlndlngs are lndlvldually ready Lhen wlndlngs are assembled on Core
1hereafLer connecLlons lnLerconnecLlons of wlndlng leads are made
AL Lhls sLage paper lnsulaLed cables copper busbars are requlred for connecLlons
AL Lhls sLage CL1C of Lransformer ls also assembled Lherefore requlred
1he compleLe assembly ls called Core Coll Assembly
1ank labrlcaLed flLLlngs Accessorles conslsLs of
Mlld SLeel
SLalnless SLeel
lpes
1ank labrlcaLed flLLlngs Accessorles are normally boughL as componenL
AfLer recelpL of Lank lnLernal flLLlngs valves eLc are mounLed on lL
1hereafLer Core Coll assembly ls puL lnslde Lhe Lank 1herefore Lank ls requlred 13
days prlor Lo readlness of core coll assembly
AfLer puLLlng Core Coll assembly lnslde Lank Lhe bushlngs are assembled Lo Lake ouL
hlgh volLage leads from lnslde Lhe Lank
AL Lhls sLage radlaLors fans pumps are needed Lo conducL 1emperaLure 8lse LesL on
Lhe Lransformer

D|spatch of 1ransformer
AfLer LesLlng Lhe Lransformer Lhe Lransformer ls prepared for dlspaLch
lL ls requlred Lo dlspaLch all Lhe flLLlngs accessorles componenLs of Lransformer along
wlLh maln Lransformer
All flLLlngs accessorles componenLs of Lransformer are Lherefore requlred
approxlmaLely one monLh prlor Lo readlness of Lransformer so LhaL Lhose can be
prepared packed for dlspaLch
1kAC1ICN 1kANSICkMLkS


All assemblles requlremenL of maLerlal componenLs and process for manufacLure for
LracLlon Lransformers ls slmllar Lo power Lransformers
1racLlon Lransformer requlre speclal Pv cable bushlng LermlnaLlon Lo connecL Lo
overhead caLenary
All Lhe maLerlal sLages of manufacLure of LracLlon Lransformer are lnspecLed by 8uSC
requlre Lhelr approval
LS 1kANSICkMLkS
1he ma[or componenLs of LS Lransformers are
Core
Wlndlng
1ank labrlcaLed flLLlngs Accessorles
1hermomeLer 8ox
Cll (ln few cases Slllcone Cll)
8adlaLors (ln few cases)
8ushlngs
lnsLrumenLs C1l 8v 8uchholz relay MCC ulode sLack 8eslsLor board ShunL reslsLor Clow
Lube
Ceneral assembly requlremenL of maLerlal componenLs and process for manufacLure
for LS Lransformers ls slmllar Lo power Lransformers
LS Lransformer addlLlonally requlre ulode SLack and 8eslsLor 8oard prlor Lo corecoll
assembly
Clow 1ube ShunL 8eslsLance are requlred before Lanklng
1he LS 1ransformer ls dlspaLched ln compleLe assembled condlLlon afLer LesLlng
Dk 1L 1kANSICkMLk
1he ma[or componenLs of ury 1ype Lransformers are
Core
Wlndlng
Lpoxy 8esln
llber Class MaL
llber Class Lnd 8locks and Cyllnders
Lnclosure
Marshalllng 8ox
Lpoxy 8ushlngs and lnsulaLors
1emperaLure Scanner and 1100
Cnly Lhe Core ls slmllar Lo power Lransformers
Lnd lrames are LlecLro Calvanlzed and boughL on flnlsh basls
1he wlndlngs are made of 8are and llber Class Lnamel lnsulaLed Copper ConducLors
Wlndlngs are made on speclal sLeel moulds wlLh llber Class MaL and Lpoxy 8esln
lnsulaLlon
lC Lnd 8locks and Cyllnders are requlred prlor Lo Corecoll assembly
Lnclosure ls requlred aL leasL 30 days before LesLlng
CoreColl assembly ls puL ln Lhe enclosure and compleLe assembled Lransformer ls
LesLed
1he ury 1ype 1ransformer ls dlspaLched ln compleLe assembled condlLlon afLer LesLlng
INS1kUMLN1
1kANSICkMLk
1he ma[or componenLs of lnsLrumenL
1ransformers are
Pollow porcelaln
lnsulaLed rlmary
conducLor (Cu Lube Al
Lube lCC)
Secondary wlndlng on
8lng Cores 'C' cores
(SynLheLlc Lnamel 8ound
Copper wlres)
1ank 1op chamber
Assembly
rlmary 1ermlnal Secondary
Lpoxy board ressure 8ellef
uevlce
Core of Lransformer conslsLs of
8lng Cores and C cores
rlmary wlndlng ls of Copper/
Alumlnum 1ube or Cable and ls
lnsulaLed for requlred volLage lL
ls manufacLured aL Lhe beglnnlng
Secondary Wlndlng on 8lng Cores are made slmulLaneously
Secondary Wlndlngs are assembled on prlmary
1he Assembly ls puL lnslde Lhe Lank and Lhe hollow porcelaln ls assembled for houslng
acLlve parL 1he Lank and fabrlcaLlon ls requlred 13 days prlor Lo Lhls assembly
1he Lop chamber ls also assembled and prlmary and secondary Lermlnals are broughL
ouL Lhrough Lermlnal sLem and secondary Lermlnal box